Hitches including latch actuators and sensors, and vehicles incorporating the same

ABSTRACT

A materials handling vehicle comprising a hitch system, and a drive mechanism. The hitch system comprises a hitch and a hitch controller. The hitch comprises a latch, one or more sensors, an actuator, and a receiving member. The latch is positionable between open and closed positions. The actuator is positionable between retracted, intermediate, and extended positions. The receiving member is configured to lead a cart hook to engage the latch when in the closed position. The one or more sensors are configured to detect a position of the latch and a presence of the cart hook received within the receiving member. The hitch controller is configured to position the actuator in one of the retracted position, the intermediate position, and the extended position, and to position the latch in one of the open position and the closed position in response to signals received from the one or more sensors.

BACKGROUND

The present disclosure relates to materials handling vehicles configuredto engage goods in a warehouse environment and move goods along aninventory transit surface in the warehouse environment. Materialshandling vehicles such as, for example, tuggers, may be unmanned andengage a cart, via a hitch, at a rear of the materials handling vehicleto navigate the cart to a target destination. However, these materialshandling vehicles may not accurately engage a cart. Maneuverability,such as a turning radius, of these materials handling vehicles may belimited by the specific manner in which the materials handling vehiclesengage the cart.

Although the concepts of the present disclosure are described hereinwith primary reference to tuggers, it is contemplated that particularconcepts of the present disclosure will enjoy applicability to pallettrucks with other types of motor configurations.

BRIEF SUMMARY

In accordance with one embodiment of the present disclosure, a materialshandling vehicle includes a hitch system, and a drive mechanism,wherein: the hitch system includes a hitch and a hitch controller; thehitch includes a latch, one or more latch sensors, a cart hook sensor,an actuator, and a receiving member; the latch is positionable betweenan open position and a closed position; the actuator is positionablebetween a retracted position, an intermediate position, and an extendedposition, and is configured to position the latch into the open positionwhen the actuator is in the extended position, position the latch intothe closed position when the actuator is in the retracted position, andpermit movement of the latch between the open position and the closedposition when the actuator is in the intermediate position; thereceiving member is configured to lead a cart hook to engage the latchwhen in the closed position; the one or more latch sensors areconfigured to detect a position of the latch; the cart hook sensor isconfigured to detect a presence of the cart hook received within thereceiving member; and the hitch controller is configured to position theactuator between the retracted position, the intermediate position, andthe extended position in response to signals received from the one ormore latch sensors and the cart hook sensor.

In accordance with another embodiment of the present disclosure, a hitchsystem includes a hitch and a hitch controller, wherein: the hitchincludes a latch, one or more latch sensors, a cart hook sensor, anactuator, and a receiving member; the latch is positionable between anopen position and a closed position; the actuator is positionablebetween a retracted position, an intermediate position, and an extendedposition, and is configured to position the latch into the open positionwhen the actuator is in the extended position, position the latch intothe closed position when the actuator is in the retracted position, andpermit movement of the latch between the open position and the closedposition when the actuator is in the intermediate position; thereceiving member is configured to lead the cart hook to engage the latchwhen in the closed position; the one or more latch sensors areconfigured to detect a position of the latch; the cart hook sensor isconfigured to detect a presence of the cart hook in the latch; and thehitch controller is configured to position the actuator between theretracted position, the intermediate position, and the extended positionin response to signals received from the one or more latch sensors andthe cart hook sensor.

In accordance with another embodiment of the present disclosure, amaterials handling vehicle includes a hitch system, and a drivemechanism, wherein: the hitch system includes a hitch and a hitchcontroller; the hitch includes a latch, one or more sensors, anactuator, and a receiving member; the latch is positionable between anopen position and a closed position; the actuator is positionablebetween a retracted position, an intermediate position, and an extendedposition; the receiving member is configured to lead a cart hook toengage the latch when in the closed position; the one or more sensorsare configured to detect a position of the latch and a presence of thecart hook received within the receiving member; and the hitch controlleris configured to position the actuator in one of the retracted position,the intermediate position, and the extended position, and to positionthe latch in one of the open position and the closed position inresponse to signals received from the one or more sensors.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following detailed description of specific embodiments of thepresent disclosure can be best understood when read in conjunction withthe following drawings, where like structure is indicated with likereference numerals and in which:

FIG. 1 schematically depicts a perspective view of a materials handlingvehicle engaging a cart, according to the present disclosure;

FIG. 2 schematically depicts a perspective view of a hitch of thematerials handling vehicle, according to the present disclosure;

FIG. 3 schematically depicts an opposite perspective view of the hitch,according to the present disclosure;

FIG. 4 schematically depicts a rear view of the hitch, according to thepresent disclosure;

FIG. 5 schematically depicts a side view of the hitch, according to thepresent disclosure;

FIG. 6 schematically depicts a cross-section view of a receiving memberof the hitch, according to the present disclosure;

FIG. 7 schematically depicts a cross-section view of the receivingmember of the hitch engaging a cart hook, according to the presentdisclosure;

FIG. 8 schematically depicts a cross-section view of the hitch in aclosed state, according to the present disclosure;

FIG. 9 schematically depicts a cross-section view of the hitch in apassive state and a latch in the closed position, according to thepresent disclosure;

FIG. 10 schematically depicts a cross-section view of the hitch in thepassive state and the latch in the open position, according to thepresent disclosure;

FIG. 11 schematically depicts a cross-section view of the hitch in anopen state, according to the present disclosure; and

FIG. 12 schematically depicts components of a hitch system, according tothe present disclosure.

DETAILED DESCRIPTION

Referring initially to FIG. 1 , a materials handling vehicle 100 isshown. The materials handling vehicle 100 includes a drive mechanism101. The materials handling vehicle 100 is configured to engage goods ina warehouse environment and the drive mechanism 120 moves goods along aninventory transit surface in the warehouse environment. Without limitingthe scope of the present disclosure, the materials handling vehicle 100may include unmanned tuggers designed to contribute to a fully automatedwarehouse solution and similar materials handling vehicles operating ina warehouse.

For the purposes of defining and describing the concepts and scope ofthe present disclosure, it is noted that a “warehouse” encompasses anyindoor or outdoor industrial facility in which materials handlingvehicles transport goods including, but not limited to, indoor oroutdoor industrial facilities that are intended primarily for thestorage of goods, such as those where multi-level racks are arranged inaisles, and manufacturing facilities where goods are transported aboutthe facility by materials handling vehicles for use in one or moremanufacturing processes.

The materials handling vehicle further includes a hitch 102 mounted to arear end 104 of the materials handling vehicle 100. As discussed in moredetail herein, the hitch 102 is configured to couple a cart 106 to thematerials handling vehicle 100 such that the materials handling vehicle100 may pull the cart 106 to a target destination.

The cart 106 includes a cart hook 108 having a first end 110 rotatablycoupled to the cart 106 and a second end 112 opposite the first end 110for engaging the hitch 102. The cart hook 108 may be rotatably coupledto the cart 106, such as by a ball joint or the like, such that the carthook 108 may move relative to the cart 106 in a lateral direction and avertical direction. The second end 112 of the cart hook 108 may includean engaging member 114 such as a ring for engaging a latch 116 of thehitch 102. The cart hook 108 includes a trailing arm 118 extending fromthe engaging member 114 to the first end 110 of the cart hook 108. Inembodiments, the trailing arm 118 is a rigid member rotatably coupled tothe cart 106 at the first end 110.

Referring now to FIGS. 2 and 3 , a perspective view of the hitch 102 isshown separate from the materials handling vehicle 100 and without thecart hook 108 engaging the latch 116. However, reference may be made tothe materials handling vehicle 100 and the cart hook 108 of FIG. 1 . Thehitch 102 generally includes a frame 120 and a receiving member 122. Thereceiving member 122 is coupled to the frame 120 such that the receivingmember 122 is mounted to the materials handling vehicle 100. Thereceiving member 122 defines a cavity 124 for receiving the second end112 of the cart hook 108, particularly the engaging member 114, and atleast partially receiving the trailing arm 118.

The frame 120 includes a back frame member 126 and an elongated framemember 128 extending substantially perpendicular to the back framemember 126. Specifically, the back frame member 126 is mounted to therear end 104 of the materials handling vehicle 100. The back framemember 126 may include a back frame member cutout 130 for permittingvarious wired connections between the hitch 102 and the materialshandling vehicle 100. In embodiments, an emergency stop 132 is providedat an upper portion of the hitch 102, particularly mounted to the backframe member 126. The emergency stop 132 is electrically connected tothe materials handling vehicle 100, particularly a motor of thematerials handling vehicle 100. As such, the emergency stop 132 may beoperated from a rear of the materials handling vehicle 100, which may beout of reach of a primary operator of the materials handling vehicle100, to immediately stop operation of the materials handling vehicle 100in a case in which a danger arises.

In embodiments, the elongated frame member 128 may include a firstelongated frame member 134 and a second elongated frame member 136spaced apart from the first elongated frame member 134. In embodiments,the frame 120 may include a medial frame member 138 extending from theback frame member 126 above the elongated frame member 128. Inembodiments, the medial frame member 138 may include a first medialframe member 140 and a second medial frame member 142 spaced apart fromthe first medial frame member 140.

The latch 116 of the hitch is positionable between an open position anda closed position. The latch 116 is at least partially received withinthe cavity 124 defined by the receiving member 122 when the latch 116 isin the closed position. In embodiments, the latch 116 may be positionedbetween the first elongated frame member 134 and the second elongatedframe member 136. Additionally, the latch 116 is pivotally attached toat least one of the first elongated frame member 134 and the secondelongated frame member 136 at a latch pivot 144.

It should be appreciated that the hitch 102 may be manually operated tobe positioned between the open position and the closed position. Inembodiments, a latch bar 146 extends from the latch 116 and between thefirst elongated frame member 134 and the second elongated frame member136. A pulling device, such as a rope, rod, or the like, may be attachedto the latch bar 146 and extend toward the materials handling vehicle100 such that an operator of the materials handling vehicle 100 may pullthe pulling device to position the latch 116 between the open positionand the closed position.

In other embodiments, the latch 116 may be mechanically positionablebetween the open position and the closed position. Accordingly, in suchembodiments, the hitch 102 may include an actuator 148 for positioningthe latch 116 between the open position and the closed position. Theactuator 148 may be coupled at a first end 150 thereof to the back framemember 126. Additionally, the actuator 148 may be positioned to extendbetween the first medial frame member 140 and the second medial framemember 142.

As discussed in more detail herein, in embodiments in which the actuator148 is provided, the actuator 148 may be positionable between aretracted position, an intermediate position, and an extended position.When the actuator 148 is positioned into the retracted position, thelatch 116 is positioned into the closed position and not permitted moveinto the open position. As referred to herein, the hitch 102 being in a“closed state” refers to a state in which the latch 116 is not permittedto move from the closed position to the open position. When the actuator148 is positioned in the extended position, the latch 116 is positionedinto the open position and not permitted move into the closed position.As referred to herein, the hitch 102 being in an “open state” refers toa state in which the latch 116 is not permitted to move from the openposition to the closed position. Lastly, when the actuator 148 ispositioned in the intermediate position, the latch 116 is freelypositionable between the open position and the closed position. Asreferred to herein, the hitch 102 being in a “passive state” refers to astate in which the latch 116 is permitted to move between the openposition to the closed position without movement of the latch 116 beingrestricted by the actuator 148.

Additionally, in embodiments in which the hitch 102 includes theactuator 148, the hitch 102 may be automatically operated to positionthe latch 116 between the open position and the closed position inresponse to signals detected by one or more sensors indicating thepresence, or lack thereof, of the cart hook 108 received within thereceiving member 122. Specifically, as discussed in more detail herein,the latch 116 may be automatically positioned into the closed positionand locked in the closed position by the actuator 148, i.e., the closedstate, in response to determining that the cart hook 108 has engaged thelatch 116. This prevents movement of the latch 116 as the materialshandling vehicle 100 traverses, for example, over a bump and the carthook 108 unintentionally disengages the latch 116. Additionally, thelatch 116 may be automatically positioned into the open position andremain in the open position by the actuator 148, i.e., the open state,to permit disengagement of the cart hook 108 from the latch 116 andremoval from the hitch 102 in response to determining that the materialshandling vehicle 100 has reached the target destination of the cart 106.

In embodiments in which the latch 116 may be automatically positionedbetween the open position and the closed position, the hitch 102 mayinclude one or more sensors. Particularly, the hitch 102 may include afirst actuator sensor 152 for detecting when the actuator 148 is in theretracted position, and a second actuator sensor 154 for detecting whenthe actuator 148 is in the intermediate position. It should beappreciated that the first actuator sensor 152 and the second actuatorsensor 154 may be incorporated into a single actuator sensor capable ofdistinguishing between the actuator 148 being the retracted position andthe intermediate position. The hitch 102 may also include a first latchsensor 156 for detecting when the latch 116 is in the closed position,and a second latch sensor 158 for detecting when the latch 116 is in theopen position. It should be appreciated that the first latch sensor 156and the second latch sensor 158 may be incorporated into a single latchsensor capable of distinguishing between the latch 116 being in theclosed position and the open position. The hitch 102 may also include acart hook sensor 160 (FIG. 6 ) for detecting the presence of the carthook 108 within the receiving member 122.

Referring now to FIGS. 4 and 5 , the receiving member 122 is mounted tothe frame 120, particularly the elongated frame member 128. Thereceiving member 122 includes a pair of inwardly curved side scoops 162and a central incline member 164 provided between the pair of inwardlycurved side scoops 162. Each inwardly curved side scoop 162 has an uppersurface 166, a lower surface 168 opposite the upper surface 166, aninner surface 170, an outer surface 172 opposite the inner surface 170,a rear surface 174, and a front surface 176 opposite the rear surface174. The rear surface 174 and the upper surface 166 of the pair ofinwardly curved side scoops 162 define an open rear end 178 of thereceiving member 122 for receiving the cart hook 108. The upper surface166 is sloped at the open rear end 178. In embodiments, the uppersurface 166 slopes both inwardly toward the central incline member 164and inwardly toward the open rear end 178.

More particularly, each of the pair of inwardly curved side scoops 162has an upper rear edge 180 formed at an intersection of the uppersurface 166 and the rear surface 174. The upper rear edge 180 extendsfrom the inner surface 170 to the outer surface 172. The upper rear edge180 has at least one of a tapered upper rear edge portion 182 and acurved upper rear edge portion 184. In embodiments, the tapered upperrear edge portion 182 extends at least partially between the innersurface 170 to the outer surface 172. In embodiments, the curved upperrear edge portion 184 is formed in the tapered upper rear edge portion182 between the inner surface 170 and the outer surface 172.Accordingly, the rear surface 174 has a first rear surface height H1 atthe inner surface 170 proximate the central incline member 164 and asecond rear surface height H2 at the outer surface 172 opposite thecentral incline member 164 greater than the first rear surface heightH1.

Each of the pair of inwardly curved side scoops 162 has an upper outeredge 186 formed at an intersection of the upper surface 166 and theouter surface 172 opposite the central incline member 164. The upperouter edge 186 has a tapered upper outer edge portion 188 extendingtoward the rear surface 174. Accordingly, the outer surface 172 has afirst outer surface height H3 at the front surface 176 greater than thesecond rear surface height H2. As discussed in more detail herein, thegradual increase in heights across the upper rear edge 180 and the upperouter edge 186 of each of the inwardly curved side scoops 162 cause thetrailing arm 118 of the cart hook 108 to ride along the upper rear edge180 and the upper outer edge 186 as the materials handling vehicle 100turns, thereby allowing a greater turning radius of the materialshandling vehicle 100 while maintaining engagement with the cart hook108. Specifically, the latch 116 extends above the upper outer edge 186of the each of the pair of inwardly curved side scoops 162 to permitengagement with the cart hook 108 above the upper outer edge 186 of theeach of the pair of inwardly curved side scoops 162. Thus, when thematerials handling vehicle 100 is in a turned position, the trailing arm118 of the cart hook 108 is positioned above the upper rear edge 180 andthe cart hook 108 maintains engagement with the latch 116.

In embodiments, a gap 190 is provided between the inner surface 170 ofeach of the pair of inwardly curved side scoops 162. The central inclinemember 164 may be provided within the gap 190. In embodiments, thecentral incline member 164 has a tapered upper surface 192 conforming toa slope of the upper surface 166 of the pair of inwardly curved sidescoops 162 at the inner surface 170 of the pair of inwardly curved sidescoops 162.

It should be appreciated that the central incline member 164 and theupper surface 166 of the pair of inwardly curved side scoops 162cooperate to lead the cart hook 108 to engage the latch 116. Moreparticularly, the engaging member 114 is guided to engage the latch 116as the trailing arm 118 enters the open rear end 178 and the cavity 124of the receiving member 122 and the engaging member 114 is notvertically and laterally aligned with the latch 116. For example, whenthe materials handling vehicle 100 and the cart 106 are moved toward oneanother and the engaging member 114 is laterally or verticallymisaligned with the latch 116, the engaging member 114 contacts theupper surface 166 of one of the pair of inwardly curved side scoops 162or the tapered upper surface 192 of the central incline member 164.Contact of the engaging member 114 with the upper surface 166 of thepair of inwardly curved side scoops 162 or the tapered upper surface 192of the central incline member 164 directs the engaging member 114 eitherlaterally and/or vertically into alignment with the latch 116.

Referring again to FIGS. 2 and 3 , in embodiments, the central inclinemember 164 includes a fixed plate 194 and one or more pivoting plates196 pivotally attached to the fixed plate 194. In embodiments, thecentral incline member 164 includes a pair of pivoting plates 196pivotally attached to opposite sides of the fixed plate 194. Each of thepivoting plates 196 are positionable between a raised position (FIG. 6 )and a lowered position (FIG. 7 ) relative to the latch 116. As shown inFIG. 6 , the pivoting plates 196 are pivotally attached to the fixedplate 194 at a central incline pivot 198. A first pivoting plate shaft200 extends through a first fixed plate opening 202 formed in the fixedplate 194 for connecting the pair of pivoting plates 196 on oppositesides of the fixed plate 194. Additionally, one or more second pivotingplate shafts 204 extend through one or more corresponding second fixedplate openings 206 for connecting the pair of pivoting plates 196 to oneanother. A biasing member 208 may be provided for biasing the pivotingplates 196 toward the raised position. The biasing member 208 may beprovided within one of the second fixed plate openings 206 or, inembodiments, at any suitable location between the pivoting plates 196and a bottom surface of the fixed plate 194. As shown, the biasingmember 208 is a spring positioned below the fixed plate 194 for biasingthe pivoting plates 196 toward the raised position.

As shown in FIGS. 6 and 7 , the pivoting plates 196 include a lobe 210extending above an upper surface 212 of the fixed plate 194 and abovethe upper surface 166 of the pair of inwardly curved side scoops 162when in the raised position, but below the upper surface 166 of the pairof inwardly curved side scoops 162 when in the lowered position. Asshown in FIG. 7 , it should be appreciated that the lobe 210 ispositioned so as to contact the engaging member 114 of the cart hook 108when the cart hook 108 is received within the cavity 124 of thereceiving member 122. Contact of the engaging member 114 with one of thelobes 210 causes one or both of the pivoting plates 196 to move towardthe lowered position.

In embodiments, a cart hook transmitter is provided at a front surfaceof one of the pivoting plates 196. More particularly, the cart hooktransmitter is positioned so as to be within a predetermined distance ofthe cart hook sensor 160 when the pivoting plates 196 are in the raisedposition such that the cart hook sensor 160 can identify that thepivoting plates 196 are in the raised position. Alternatively, as shownin FIG. 7 , when the pivoting plates 196 are in the lowered position,such as when the cart hook 108 engages the latch 116, the cart hooktransmitter is vertically displaced relative to the cart hook sensor 160such that the cart hook sensor 160 does not identify the presence of thecart hook transmitter. Accordingly, the cart hook sensor 160 isconfigured to detect the presence of the cart hook 108 received withinthe receiving member 122 when the cart hook sensor 160 does not identifythe presence of the cart hook transmitter, i.e., when the pivotingplates 196 are in the lowered position. Additionally, the cart hooksensor 160 may be configured to detect the lack of presence of the carthook 108 within the receiving member 122 when the cart hook sensor 160does identify the presence of the cart hook transmitter, i.e., when thepivoting plates 196 are in the raised position.

Referring now to FIG. 8 , the latch 116 has a latch tooth end 214 and alatch pivoting end 216 opposite the latch tooth end 214. The latch toothend 214 at least partially extends into the cavity 124 defined by thepair of inwardly curved side scoops 162 when the latch 116 is in theclosed position. The latch tooth end 214 defines a latch rear surface218 having a taper formed therein. The latch 116 is pivotally attachedto the elongated frame member 128 at the latch pivot 144. The latch 116has a latch finger 220 extending from the latch pivoting end 216. Thelatch finger 220 may include a latch transmitter for transmitting asignal to the first latch sensor 156 and the second latch sensor 158 foridentifying a position of the latch 116 either in the open position orthe closed position. When the hitch 102 is in the passive state, suchthat the latch 116 is in the closed position and permitted to move tothe open position, contact by the engaging member 114 on the latch rearsurface 218 will result in rotation of the latch 116 toward the openposition and engagement with the cart hook 108.

Referring still to FIG. 8 , the latch 116 at least partially defines acart hook receiving space 213 positioned at least partially above theupper outer edge 186 of the pair of inwardly curved side scoops 162 whenthe latch 116 is in the closed position. The cart hook receiving space213 is configured to receive the cart hook 108. In embodiments, the carthook receiving space 213 is at least partially defined by the latchtooth end 214 of the latch 116, a latch body wall 215 of the latch 116extending from the latch tooth end 214, and an upstanding front wall 217of the receiving member 122. Due to the latch tooth end 214 of the latch116 extending partially into the cavity 124 defined by the pair ofinwardly curved side scoops 162 when the latch 116 is in the closedposition, the cart hook receiving space 213 is positioned at leastpartially below the upper outer edge 186 of the pair of inwardly curvedside scoops 162 when the latch 116 is in the closed position.

In embodiments, the latch 116 defines a latch cutout 222 formed in thelatch 116 and extending between the latch tooth end 214 and the latchpivoting end 216. The latch cutout 222 may have an elliptical geometryand extends through opposite sides of the latch 116. In otherembodiments, the latch cutout 222 may include a plurality of cutoutsformed between the latch tooth end 214 and the latch pivoting end 216such as, for example, a plurality of holes. The latch cutout 222 reducesa weight of the latch 116, thereby shifting the center of gravity of thelatch 116 closer to the latch pivot 144 and facilitating pivoting of thelatch 116 from the closed position to the open position upon contact ofthe cart hook 108.

Referring now to FIGS. 8-11 , the latch 116 has a latch pin 224, whichengages an actuator slot 226 formed in an end of the actuator 148. Theactuator slot 226 extends along a longitudinal direction of the actuator148 and has a lower end 228 and an upper end 230 opposite the lower end228. As shown in FIG. 8 , the hitch 102 is in the closed state such thatthe actuator 148 is in the retracted position and the latch 116 is inthe closed position. Thus, the latch pin 224 is positioned at the lowerend 228 of the actuator slot 226. In the closed state, the latch 116 isprohibited from pivoting about the elongated frame members 128 and intothe open position. More specifically, the lower end 228 of the actuatorslot 226 functions as a stop to prevent rotation of the latch 116 intothe open position. When the latch 116 is in the closed position, asshown, the first latch sensor 156 (FIG. 5 ) detects the presence of thelatch finger 220, thus identifying that the latch 116 is in the closedposition. As shown in FIGS. 9 and 10 , the hitch 102 is in the passivestate such that the actuator 148 is in the intermediate position and thelatch 116 is permitted to move between the open position and the closedposition. Specifically, in FIG. 9 , the actuator 148 is in theintermediate position and the latch 116 is in the closed position. Itshould be appreciated that an amount of extension of the actuator 148when in the intermediate position is greater than an amount of extensionof the actuator 148 when in the retracted position, but less than anamount of extension when in the extended position. When the actuator 148is in the intermediate position and the latch 116 is in the closedposition, the latch pin 224 is located closer to the upper end 230 ofthe actuator slot 226 compared to when the actuator 148 is in theintermediate position and the latch 116 is in the open position, asshown in FIG. 10 . Additionally, when the actuator 148 is in theintermediate position and the latch 116 is in the closed position, thelatch pin 224 is located closer to the upper end 230 of the actuatorslot 226 as compared to when the actuator 148 is in the retractedposition and the latch 116 is in the closed position. As shown in FIG.11 , the hitch 102 is in the open state such that the actuator 148 is inthe extended position and the latch 116 is in the open position. Thus,the latch pin 224 is positioned at the upper end 230 of the actuatorslot 226. In the open state, the latch 116 is prohibited from pivotingabout the elongated frame member 128 and into the closed position. Itshould be appreciated that the upper end 230 of the actuator slot 226pushes the latch pin 224 forcing the latch 116 into the open position.As such, the upper end 230 of the actuator slot 226 functions as a stopto prevent rotation of the latch 116 into the closed position. When thelatch 116 is in the open position, as shown, the second latch sensor 158(FIG. 5 ) detects the presence of the latch finger 220, thus identifyingthat the latch 116 is in the open position.

As discussed herein, in embodiments in which the hitch 102 may beautomatically operated to detect the presence of a cart hook 108 withinthe receiving member 122 and controlling the actuator 148 to accordinglyposition the latch 116 into the open position and the closed position,the hitch 102 may include a plurality of sensors for detecting positionsof various components of the hitch 102.

As discussed herein and referring again to FIG. 5 , the hitch 102includes the first latch sensor 156 configured to detect that the latch116 is in the closed position, and the second latch sensor 158configured to detect that the latch 116 is in the open position. Thefirst latch sensor 156 and the second latch sensor 158, as shown, aremounted to either one or both of the elongated frame members 128. Alatch sensor slot 232 is formed in either one or both of the elongatedframe members 128 to permit the first latch sensor 156 and the secondlatch sensor 158 to identify the presence of the latch finger 220 of thelatch 116 when in the open position and the closed position.

The hitch 102 also includes the first actuator sensor 152 (FIG. 3 )configured to detect that the actuator 148 is in the retracted positionand the second actuator sensor 154 configured to detect that theactuator 148 is in the intermediate position. The first actuator sensor152 and the second actuator sensor 154, as shown, are mounted to eitherone of the medial frame members 138. An actuator sensor slot 234 isformed in either one or both of the medial frame members 138 to permitthe first actuator sensor 152 and the second actuator sensor 154 toidentify the presence of the actuator 148 when in the retracted positionand the intermediate position, respectively. It should be appreciatedthat it may be determined that actuator 148 is in the extended positionmerely when no determination is made that the actuator 148 is in theretracted position or the intermediate position. Alternatively, a thirdactuator sensor may be positioned on a side of the second actuatorsensor 154 opposite the first actuator sensor 152 for specificallydetermining that the actuator 148 is in the extended position.

Lastly, the hitch 102 includes the cart hook sensor 160 configured todetect that the pivoting plates 196 of the receiving member 122 are inthe raised position. Specifically, the cart hook sensor 160 isconfigured to detect the presence of the cart hook 108 received withinthe receiving member 122. The cart hook sensor 160 may be mounted to oneor both of the elongated frame members 128. As discussed herein, thecart hook sensor 160 detects that the cart hook 108 is received withinthe receiving member 122 when the one or more pivoting plates 196 is inthe lowered position, and the cart hook sensor 160 detects that a carthook 108 is not received within the receiving member 122 when the one ormore pivoting plates 196 is in the raised position.

It should be appreciated that the sensors discussed herein may be anysuitable sensor for detecting the presence of a component. For example,the sensors may be proximity sensors for detecting the presence of acorresponding component, motion sensors for detecting when acorresponding component is moved into range of the sensor, or a sensorreceiving a signal from a transmitter mounted onto the correspondingcomponent. Additional types of sensors not specifically disclosed hereinare within the scope of the present disclosure.

Referring still to FIG. 5 , each of the first latch sensor 156, thesecond latch sensor 158, the first actuator sensor 152, the secondactuator sensor 154, and the cart hook sensor 160 may be movably mountedto the hitch 102 such that a vertical position of the sensors may beadjusted to accurately detect a corresponding component, such as theactuator 148, the latch 116, or the pivoting plates 196, respectively.Specifically, a first latch sensor mount 236 is provided for movablymounting the first latch sensor 156 to the hitch 102, a second latchsensor mount 238 is provided for movably mounting the second latchsensor 158 to the hitch 102, a first actuator sensor mount 240 isprovided for movably mounting the first actuator sensor 152 to the hitch102, and a second actuator sensor mount 242 is provided for movablymounting the second actuator sensor 154 to the hitch 102. It should beappreciated that the structure of the first latch sensor mount 236, thesecond latch sensor mount 238, the first actuator sensor mount 240, andthe second actuator sensor mount 242 have identical structure and thusonly the structure of the first actuator sensor mount 240 is discussedin detail herein.

The first latch sensor mount 236 includes a mount body 244 having afirst end 246 pivotally attached to the hitch 102, particularly one orboth of the elongated frame members 128, and a second end 248 oppositethe first end 246. The first latch sensor 156 extends through the mountbody 244 between the first end 246 and the second end 248 and is fixedthereto. An arcuate slot 250 is formed at the second end 248 and anadjustable fastener 252 extends through the arcuate slot 250 for fixingthe mount body 244 relative to the hitch 102. As the adjustable fastener252 is loosened, the mount body 244 is permitted to rotate about thefirst end 246 of the mount body 244. Pivoting of the mount body 244 in afirst direction will raise the vertical position of the first latchsensor 156 while pivoting of the mount body 244 in an opposite seconddirection will lower the vertical position of the first latch sensor156.

Although not shown in detail, a cart hook sensor mount 254 is alsoprovided for movably mounting the cart hook sensor 160 to the hitch 102and permitting adjustment of a vertical position of the cart hook sensor160.

Referring now to FIG. 12 , a schematic diagram of an automatic hitchsystem 300 is depicted illustrating individual hardware componentsthereof, as discussed herein and with reference to FIGS. 1-11 . Inembodiments, the automatic hitch system 300 includes a hitch controller302, a communication path 304, and network interface hardware 306. Thecommunication path 304 may be formed from any medium that is capable oftransmitting a signal such as, for example, conductive wires, conductivetraces, optical waveguides, or the like. Moreover, the communicationpath 304 may be formed from a combination of mediums capable oftransmitting signals. In one embodiment, the communication path 304includes a combination of conductive traces, conductive wires,connectors, and buses that cooperate to permit the transmission ofelectrical data signals to components such as processors, memories,sensors, input devices, output devices, and communication devices.Additionally, it is noted that the term “signal” means a waveform (e.g.,electrical, optical, magnetic, mechanical or electromagnetic), such asDC, AC, sinusoidal-wave, triangular-wave, square-wave, vibration, andthe like, capable of traveling through a medium. The communication path304 communicatively couples the various components of the automatichitch system 300. As used herein, the term “communicatively coupled”means that coupled components are capable of exchanging data signalswith one another such as, for example, electrical signals via conductivemedium, electromagnetic signals via air, optical signals via opticalwaveguides, and the like.

As noted above, the automatic hitch system 300 includes the hitchcontroller 302 including one or more processors 308 and one or morememory modules 310. Each of the one or more processors 308 may be anydevice capable of executing machine readable instructions. Accordingly,each of the one or more processors 308 may be an integrated circuit, amicrochip, a computer, or any other computing device. The one or moreprocessors 308 are communicatively coupled to the other components ofthe automatic hitch system 300 by the communication path 304.Accordingly, the communication path 304 may communicatively couple anynumber of processors with one another, and allow the modules coupled tothe communication path 304 to operate in a distributed computingenvironment. Specifically, each of the modules may operate as a nodethat may send and/or receive data.

Each of the one or more memory modules 310 of the automatic hitch system300 is coupled to the communication path 304 and communicatively coupledto the one or more processors 308. The one or more memory modules 310may include RAM, ROM, flash memories, hard drives, or any device capableof storing machine readable instructions such that the machine readableinstructions may be accessed and executed by the one or more processors308. The machine readable instructions may include logic or algorithm(s)written in any programming language of any generation (e.g., 1GL, 2GL,3GL, 4GL, or 5GL) such as, for example, machine language that may bedirectly executed by the processor, or assembly language,object-oriented programming (OOP), scripting languages, microcode, etc.,that may be compiled or assembled into machine readable instructions andstored on the one or more memory modules 310. In some embodiments, themachine readable instructions may be written in a hardware descriptionlanguage (HDL), such as logic implemented via either afield-programmable gate array (FPGA) configuration or anapplication-specific integrated circuit (ASIC), or their equivalents.Accordingly, the methods described herein may be implemented in anyconventional computer programming language, as pre-programmed hardwareelements, or as a combination of hardware and software components.

As noted above, the automatic hitch system 300 includes the networkinterface hardware 306 for wirelessly communicatively coupling theautomatic hitch system 300 with other communication devices, such as acentral server, a mobile device, and the like. The network interfacehardware 306 is coupled to the communication path 304 such that thecommunication path 304 communicatively couples the network interfacehardware 306 to other modules of the automatic hitch system 300. Thenetwork interface hardware 306 may be any device capable of transmittingand/or receiving data via a wireless network. Accordingly, the networkinterface hardware 306 may include a communication transceiver forsending and/or receiving data according to any wireless communicationstandard. For example, the network interface hardware 306 may include achipset (e.g., antenna, processors, machine readable instructions, etc.)to communicate over wireless computer networks such as, for example,wireless fidelity (Wi-Fi), WiMax, Bluetooth®, IrDA, Wireless USB,Z-Wave, ZigBee, or the like. In some embodiments, the network interfacehardware 306 includes a Bluetooth® transceiver that enables theautomatic hitch system 300 to exchange information with a mobile devicesuch as, for example, a smartphone, via Bluetooth® communication.

In embodiments, the automatic hitch system 300 further includes theactuator 148, the first actuator sensor 152, the second actuator sensor154, the first latch sensor 156, the second actuator sensor 154, and thecart hook sensor 160. The actuator 148, the first actuator sensor 152,the second actuator sensor 154, the first latch sensor 156, the secondactuator sensor 154, and the cart hook sensor 160 may be coupled to thecommunication path 304 such that the communication path 304communicatively couples the actuator 148, the first actuator sensor 152,the second actuator sensor 154, the first latch sensor 156, the secondactuator sensor 154, and the cart hook sensor 160 to other modules ofthe automatic hitch system 300.

In embodiments, the automatic hitch system 300 further includes alocation sensor 312 for determining a location of the hitch 102. Thelocation sensor 312 may be coupled to the communication path 304 suchthat the communication path 304 communicatively couples the locationsensor 312 to other modules of the automatic hitch system 300. Thelocation sensor 312 may be, for example, a GPS module, configured tocapture location data indicating a location of the hitch 102, which maybe transmitted to the hitch controller 302. The location data may becompared to location data of a cart pickup location to identify that thematerials handling vehicle 100 has arrived at the cart 106, and/or atarget destination to identify that the materials handling vehicle 100has arrived at a final destination of the cart 106.

In embodiments, the hitch controller 302 determines whether thematerials handling vehicle 100 has arrived at the pickup location of thecart 106. In embodiments, the hitch controller 302 determines theposition of the actuator 148, the position of the latch 116, and whetherthe cart hook 108 is received within the receiving member 122.Specifically, the hitch controller 302 determines whether the actuator148 is in the retracted position or the intermediate position based onsignals received from the first actuator sensor 152 and the secondactuator sensor 154. In embodiments, the hitch controller 302 maydetermine when the actuator 148 is in the extended position based on afailure to determine that the actuator 148 is in one of the retractedposition and the intermediate position. Additionally, the hitchcontroller 302 determines whether the latch 116 is in the closedposition or the open position based on signals received from the firstlatch sensor 156 and the second latch sensor 158 detecting the latchfinger 220 of the latch 116. Lastly, the hitch controller 602 determineswhether the cart hook 108 is received within the receiving member 122based on signals received from the cart hook sensor 160 indicating thatthe pivoting plates 196 are in the lowered position.

Based on the above determinations made by the hitch controller 302, theactuator 148 may be operated to permit the cart hook 108 to engage thelatch 116 at the pickup location, maintain engagement with the cart hook108 until the materials handling vehicle 100 has reached the targetdestination, and disengage the cart hook 108 upon reaching the targetdestination.

Specifically, in response to detecting that the materials handlingvehicle 100 has arrived at the pickup location of the cart 106, theactuator 148 may be positioned into the intermediate position such thatthe hitch 102 is in the passive state and the latch 116 is capable ofreceiving the cart hook 108 upon contact of the engaging member 114 ofthe cart hook 108 with the latch rear surface 218 of the latch 116. Thehitch controller 302 determines that the actuator 148 is in theintermediate position in response to no signal being received from oneor more of the first actuator sensor 152 and the second actuator sensor154. When the actuator 148 is in the intermediate position, the hitchcontroller 302 is configured to determine whether the latch 116 is inthe closed position in response to receiving a signal from the firstlatch sensor 156 and that the latch 116 is in the open position inresponse to receiving a signal from the second latch sensor 158.

In response to receiving a signal from the cart hook sensor 160 that thepivoting plates 196 are in the lowered position, the hitch controller302 determines that the cart hook 108 is positioned within the receivingmember 122 and engaged with the latch 116. As a secondary verificationmethod for confirming that the cart hook 108 is positioned within thereceiving member 122 and engaged with the latch 116, the hitchcontroller 302 identifies that the latch 116 moved from the closedposition, to the open position, and back to the closed position inresponse to respective signals received from the first latch sensor 156indicating the latch 116 is initially in the closed position,subsequently receiving a signal from the second latch sensor 158indicating the latch 116 is moved into the open position oralternatively a lack of signal received from the first latch sensor 156,and subsequently receiving another signal from the first latch sensor156 indicating the latch 116 is back in the closed position. The hitchcontroller 302 may receive the signal from the cart hook sensor 160 whenthe latch 116 is subsequently positioned back into closed position. Thissecondary verification method is useful in instances in which one ormore of the latch 116 and the pivoting plates 196 change positions, suchas for example when the materials handling vehicle 100 travels over abump, without actually receiving the cart hook 108.

As discussed herein, the hitch controller 302 is configured to positionthe actuator 148 between the retracted position, the intermediateposition, and the extended position in response to receiving signalsfrom the first latch sensor 156, the second latch sensor 158, and/or thecart hook sensor 160. As such, in response to the hitch controller 302determining that the cart hook 108 has engaged the latch 116, theactuator 148 may be positioned into the retracted position such that thehitch 102 is in the closed state and the latch 116 is not permitted tomove to the open position.

Upon the hitch controller 302 determining that the materials handlingvehicle 100 has arrived at the target destination based on the locationdata received from the location sensor 312, the hitch controller 302 maybe configured to position the actuator 148 into the extended position.As discussed herein, positioning the actuator 148 into the extendedposition forces the latch 116 into the open position. As such, thematerials handling vehicle 100 may be moved in a direction away from thecart 106 to disengage the cart 106 from the hitch 102. Once the hitchcontroller 302 determines that the cart hook 108 is no longer engagedwith the latch 116 and received within the receiving member 122, such asindicated by the cart hook sensor 160, the hitch controller 302 mayposition the actuator 148 into the intermediate position to permit thelatch 116 to freely move between the closed position and the openposition.

It is also noted that recitations herein of “at least one” or “one ormore” component, element, etc., should not be used to create aninference that the alternative use of the articles “a” or “an” should belimited to a single component, element, etc.

It is noted that recitations herein of a component of the presentdisclosure being “configured” in a particular way, to embody aparticular property, or to function in a particular manner, arestructural recitations, as opposed to recitations of intended use. Morespecifically, the references herein to the manner in which a componentis “configured” denotes an existing physical condition of the componentand, as such, is to be taken as a definite recitation of the structuralcharacteristics of the component.

Having described the subject matter of the present disclosure in detailand by reference to specific embodiments thereof, it is noted that thevarious details disclosed herein should not be taken to imply that thesedetails relate to elements that are essential components of the variousembodiments described herein, even in cases where a particular elementis illustrated in each of the drawings that accompany the presentdescription. Further, it will be apparent that modifications andvariations are possible without departing from the scope of the presentdisclosure, including, but not limited to, embodiments defined in theappended claims. More specifically, although some aspects of the presentdisclosure are identified herein as preferred or particularlyadvantageous, it is contemplated that the present disclosure is notnecessarily limited to these aspects.

It is noted that one or more of the following claims utilize the term“wherein” as a transitional phrase. For the purposes of defining thepresent invention, it is noted that this term is introduced in theclaims as an open-ended transitional phrase that is used to introduce arecitation of a series of characteristics of the structure and should beinterpreted in like manner as the more commonly used open-ended preambleterm “comprising.”

What is claimed is:
 1. A materials handling vehicle comprising a hitchsystem, and a drive mechanism, wherein: the hitch system comprises ahitch and a hitch controller; the hitch comprises a latch, one or morelatch sensors, a cart hook sensor, an actuator, and a receiving member;the latch is positionable between an open position and a closedposition; the actuator is positionable between a retracted position, anintermediate position, and an extended position, and is configured toposition the latch into the open position when the actuator is in theextended position, position the latch into the closed position when theactuator is in the retracted position, and permit movement of the latchbetween the open position and the closed position when the actuator isin the intermediate position; the receiving member is configured to leada cart hook to engage the latch when in the closed position; the one ormore latch sensors are configured to detect a position of the latch; thecart hook sensor is configured to detect a presence of the cart hookreceived within the receiving member; and the hitch controller isconfigured to position the actuator between the retracted position, theintermediate position, and the extended position in response to signalsreceived from the one or more latch sensors and the cart hook sensor. 2.The materials handling vehicle of claim 1, further comprising: a firstactuator sensor configured to detect that the actuator is in theretracted position; and a second actuator sensor configured to detectthat the actuator is in the intermediate position, wherein the hitchcontroller determines that the actuator is in the extended position inresponse to no signal being received from one or more of the firstactuator sensor and the second actuator sensor.
 3. The materialshandling vehicle of claim 1, wherein the one or more latch sensorscomprises: a first latch sensor configured to detect that the latch isin the closed position; and a second latch sensor configured to detectthat the latch is in the open position.
 4. The materials handlingvehicle of claim 3, further comprising: a first latch sensor mount formovably mounting the first latch sensor to the hitch; and a second latchsensor mount for movably mounting the second latch sensor to the hitch,wherein the first latch sensor mount and the second latch sensor mounteach comprise: a mount body having a first end pivotally attached to thehitch and a second end opposite the first end, an arcuate slot formed atthe second end; and an adjustable fastener extending through the arcuateslot for fixing the mount body relative to the hitch.
 5. The materialshandling vehicle of claim 4, wherein the first latch sensor mount andthe second latch sensor mount are each operable to adjust a verticalposition of the first latch sensor and the second latch sensor,respectively.
 6. The materials handling vehicle of claim 3, wherein thereceiving member comprises: a pair of inwardly curved side scoops; and acentral incline member provided between the pair of inwardly curved sidescoops, the central incline member comprising: a fixed plate; and one ormore pivoting plates pivotally attached to the fixed plate, the one ormore pivoting plates positionable between a raised position and alowered position relative to the latch.
 7. The materials handlingvehicle of claim 6, wherein the cart hook sensor detects that the carthook is received within the receiving member when the one or morepivoting plates is in the lowered position, and wherein the cart hooksensor detects that the cart hook is not received within the receivingmember when the one or more pivoting plates is in the raised position.8. The materials handling vehicle of claim 7, wherein the one or morepivoting plates comprises a lobe extending above an upper surface of thefixed plate when in the raised position and below the upper surface ofthe fixed plate when in the lowered position.
 9. The materials handlingvehicle of claim 7, wherein the hitch controller is configured toposition the actuator into the retracted position when the cart hooksensor sends a signal indicating that the cart hook is received withinthe receiving member.
 10. The materials handling vehicle of claim 7,wherein the hitch controller is configured to position the actuator intothe intermediate position when the cart hook sensor does not send asignal indicating that the cart hook is received within the receivingmember.
 11. The materials handling vehicle of claim 7, wherein the hitchcontroller is configured to position the actuator into the extendedposition when a signal is received indicating that the materialshandling vehicle has reached a cart destination.
 12. The materialshandling vehicle of claim 7, wherein the hitch controller is configuredto determine that the cart hook is received within the receiving memberwhen a signal is received from the cart hook sensor, and a signal issubsequently received from the first latch sensor.
 13. The materialshandling vehicle of claim 1, wherein the receiving member furthercomprises: a pair of inwardly curved side scoops; and a central inclinemember provided between the pair of inwardly curved side scoops, eachinwardly curved side scoop having an upper surface, a lower surfaceopposite the upper surface, an inner surface, an outer surface oppositethe inner surface, a rear surface, and a front surface opposite the rearsurface.
 14. The materials handling vehicle of claim 13, wherein therear surface and the upper surface of the pair of inwardly curved sidescoops define an open rear end of the receiving member, the uppersurface being sloped at the open rear end, and wherein the centralincline member and the upper surface of the pair of inwardly curved sidescoops cooperate to lead the cart hook to engage the latch.
 15. Thematerials handling vehicle of claim 13, wherein each of the pair ofinwardly curved side scoops has an upper rear edge formed at anintersection of the upper surface and the rear surface, the upper rearedge extending from the inner surface to the outer surface, the upperrear edge having a tapered upper rear edge portion extending at leastpartially between the inner surface to the outer surface.
 16. Thematerials handling vehicle of claim 13, wherein a trailing arm of thecart hook is guided to ride up one of the pair of inwardly curved sidescoops as the materials handling vehicle turns relative to the carthook.
 17. The materials handling vehicle of claim 16, wherein thetrailing arm of the cart hook is guided to ride along an upper rear edgeof one of the pair of inwardly curved side scoops and subsequently anupper outer edge of the one of the pair of inwardly curved side scoopsas the materials handling vehicle turns relative to the cart hook. 18.The materials handling vehicle of claim 1, wherein the latch has a latchpin engaging an actuator slot formed in an end of the actuator, andwherein, when the actuator is in the extended position, an upper end ofthe actuator slot pushes the latch pin forcing the latch into the openposition.
 19. A hitch system comprising a hitch and a hitch controller,wherein: the hitch comprises a latch, one or more latch sensors, a carthook sensor, an actuator, and a receiving member; the latch ispositionable between an open position and a closed position; theactuator is positionable between a retracted position, an intermediateposition, and an extended position, and is configured to position thelatch into the open position when the actuator is in the extendedposition, position the latch into the closed position when the actuatoris in the retracted position, and permit movement of the latch betweenthe open position and the closed position when the actuator is in theintermediate position; the receiving member is configured to lead thecart hook to engage the latch when in the closed position; the one ormore latch sensors are configured to detect a position of the latch; thecart hook sensor is configured to detect a presence of the cart hook inthe latch; and the hitch controller is configured to position theactuator between the retracted position, the intermediate position, andthe extended position in response to signals received from the one ormore latch sensors and the cart hook sensor.
 20. A materials handlingvehicle comprising a hitch system, and a drive mechanism, wherein: thehitch system comprises a hitch and a hitch controller; the hitchcomprises a latch, one or more sensors, an actuator, and a receivingmember; the latch is positionable between an open position and a closedposition; the actuator is positionable between a retracted position, anintermediate position, and an extended position; the receiving member isconfigured to lead a cart hook to engage the latch when in the closedposition; the one or more sensors are configured to detect a position ofthe latch and a presence of the cart hook received within the receivingmember; and the hitch controller is configured to position the actuatorin one of the retracted position, the intermediate position, and theextended position, and to position the latch in one of the open positionand the closed position in response to signals received from the one ormore sensors.